2017 Ford Expedition driver blend door actuator replacement

[fintoad]

Clicking from front driver side, above your right knee. I found it was the driver blend door actuator. I bought a replacement and when it arrived, I found it wouldn't fit due to connector different and rounded body vice square body. I bought the correct one only to find out it did not fit. I compared old/new and exactly same. I tried putting the old one in and same thing (Huh? Yeah). Spent 2 days after work and no luck. The actuator has a locating slot, so only one way to mount. If I align mounting holes, the gear is above the hole mount gear in hole, mounting holes don't align?? Anyone have pic of what there's looks like? I slide my seat back and bend over backwards to work on it.

 

[Lost_Penguin_Expy]

Long overdue reply.... I will be replacing mine for the third time in a year tomorrow. I ran into the same issue the first time i changed one out. What I had to do was connect the power to the unit and turn the key on, that cause it to engage and start turning the gear drive. I had to do it a couple time to get the locating tooth gap to align close enough to get it started.
I the last two replacement units were AutoZone DuraLast brand. I was able to get a warranty replacement the second time I replaced it due to the DuraLast failure. I am going to just try and get my money back this time and go FoMoCO part for OEM replacement and hope it lasts a little longer!

 

[BigOleFordFan]

I had both sides replaced about 2 yrs ago with FoMoCo parts, nottaproblemo since then

 

[Cluster333]

When I did a 2016 Taurus SHO I found this video on you tube

2015 Ford Taurus - Defrost/Vent/Floor Actuator, a trick to align​

Not sure if it will work for the Expedition. For me tight space and gravity was no help this is what I did to hold it while putting bolts back in or to hold the wheel to get it up into the hole to get it lined up.​